Caterpillar Natural Gas Compression Engines Library Section .ppt

Caterpillar Natural Gas Compression Engines Library Section 5 060427.ppt

Feature & Benefits G3600 Family Slides


G3600 Family Slides Reliability Durability Flexibility of Application Easy to Package Easy to Maintain Emissions Capability Transportable


G3600 Family G3606:

1775 - 1895 bhp

G3608: 2370 - 2520 bhp

Bore x Stroke: 300 x 300 mm (11.8 x 11.8 in) G3612:

3550 - 3785 bhp

G3616: 4735 - 5045 bhp


Reliability

Caterpillar ADEM A3 control system with detonation-sensitive timing control for individual cylinders

Robust diesel strength design provides prolonged life and lower owning and operating costs.

G3600 Family Slides


TPS57 vs. VTC254 Turbo

TPS57 Turbo is now standard on all G3600 engines New TPS design is radial exhaust flow, weight is centered

and it’s less likely to have build up on blades Benefit - Improved turbo life for increased uptime

Durability

G3600 Family Slides

VTC vs TPS

Turbos


Flexibility of Application

G3600 Fuel SystemFuel/Air Mixing

Main chamber fuel supplied through gas admission valve in cylinder air inlet elbow

Electronic fuel metering – Throttle plate on the fuel line - control of

fuel supply pressure relative to inlet air pressure

Benefit Speed/load control = stable + responsive


G3600 Hp Range

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

1000 rpm 900 rpm 800 rpm 750 rpm

Hp

G3606 LE 32C G3606 LE 54CG3608 LE 32CG3608 LE 54CG3612 LE 32CG3612 LE 54CG3616 LE 32CG3616 LE 54C


Caterpillar Natural Gas Compression Engines Library Section 5 060427.pptAriel & Cat 1000 RPM Matchup

0 1000 2000 3000 4000 5000 6000 7000 8000 9000

G3616

JGB/6-1000 RPM

JGZ/6-1000 RPM

G3612

JGC/6-1000 RPM

JGB/4-1000 RPM

G3608

JGZ/4-1000 RPM

JGC/4-1000 RPM

G3606

JGK/6-1000 RPM

JGB/2-1000 RPM

JGZ/2-1000 RPM

JGK/4-1000 RPM

JGC/2-1000 RPM

BHP85% to 100% Rated Engine

50% to 85% Rated Engine HP

50% to 70% Rated Comp HP

70% to 100% Rated Comp HP



Altitude Derate Factors

50%

60%

70%

80%

90%

100%

110%

0 2000 4000 6000 8000 10000 12000

Altitude (ft)

Dera

te F

acto

r

120 F90 F60 F

G3606 @ 1895 hpHigh Altitude Capability (0 - 12,000) ft



G3606 @ 1895 hp



G3606 @ 1895 hp25% Speed turndown @ constant torque




50%

60%

70%

80%

90%

100%

110%

0 2000 4000 6000 8000 10000 12000

Altitude (ft)

Dera

te F

acto

r

120 F90 F60 F




G3608 @ 2520 hp




50%

60%

70%

80%

90%

100%

110%

0 2000 4000 6000 8000 10000 12000

Altitude (ft)

Dera

te F

acto

r

120 F90 F60 F




G3612 @ 3785 hpFlexibility of Application



50%

60%

70%

80%

90%

100%

110%

0 2000 4000 6000 8000 10000 12000

Altitude (ft)

Dera

te F

acto

r

120 F90 F60 F




G3616 @ 5045 hpFlexibility of Application


Easy to Package

Integrated control of ignition, air, and fuel (has four separate control boxes tied into one)Benefit – All controlled by one system.

G3600 Family Slides


Easy to Maintain

Integrated control of ignition, air, and fuel (has four separate control boxes tied into one)Benefit – – Lower O&O costs– All controlled by one system.

G3600 Family Slides


G3600 Serviceability Crankcase inspection covers

Service ports– Oil & Coolant

Segmented camshaft – Ease of service

Easy spark plug access – Plug comes in through the side of the head– Benefit - Easier Serviceability = Lower

Maintenance Costs

Pressurized cooling system– Helps prevent cavitation– Reduces risk of boiling

Excellent top end life


Emissions Capability

Integrated control of ignition, air, and fuel (has four separate control boxes tied into one)Benefit - low N0x emissions

G3600 Family Slides


Engine Hp NOx NOx w/ Catalyst

CO CO w/ Catalyst

NMHC NMHC w/ Catalyst

G3606 1895 .7 .07 2.5 .025 1.53 .153

G3608 2520 .7 .07 2.5 .025 1.48 .148

G3612 3785 .7 .07 2.5 .025 5.6 .056

G3616 5045 .7 .07 2.5 .025 1.48 .148

Catalyst OptionEmissions Capability

G3600 Family Slides


G3600 Fuel System — Lean Combustion

Pre-chamber

Check Valve

Main Chamber

Fuel-enriched pre-combustion chamber

– centrally located with 8 nozzle holes

Ultra-lean main combustion chamber

Real-time main chamber combustion monitoring

Spark timing- optimized vs. speed

and load

– Best efficiency

Benefit - Lower emissions

– Takes lower energy to ignite rich mixture in pre-chamber – Longer spark plug life

Spark Plug


G3600 Combustion Probe Used to measure flame speed

Adjustments to air/fuel ratio made

based on probe readings

Benefit - More efficient fuel use,

helps maintain NOx

Probe


Transportable

May move by ground by truck with special permits

G3600 Family Slides


ADEM A3 Controls for G3600’s


Control System Standardization – Why? Different control systems used on different engine platforms

– G3600 Caterpillar Ignition System + Engine Supervisory System (ESS)– G3500 Caterpillar Electronic Ignition System (EIS) + Status Control– G3300/G3400 magneto ignition + manual


Control System Standardization – Why A3? G3600 Engine Supervisory System (ESS) was very complex

– Many components– Hard to troubleshoot– Limited expandability

ADEM A3 control adapted from existing diesel engine system– Fully redeveloped for gas engine specific needs– More modern electronics exploited to simplify system architecture

while expanding system functionality


Control System Standardization – Why A3? G3600 platform received a performance increase

– Fully integrated system incorporating ignition, governing, and protection in a centralized system

– ADEM A3 migration from diesel product to G3600 well received

G3500 platforms needed more capable controls to drive more advanced ignition and fuel systems

– ADEM A3 system adapted from G3600 platform to give the comprehensive control needed for G3500


G3600 ADEM A3 Control System


Gas Engine Control Module Engine Control Module (ECM) provides

total engine control from one source– Ignition– Governing– Air/fuel ratio control– Start/stop logic & engine protection– Communications (via PL1000 module)– “Flash” programmable software

Compatible With Electronic Technician


Gas Engine Control Module Mounted in NEMA 4

watertight enclosure Includes door-mounted

E-stop push button Continuous lead ignition

primaries run from module to coil without a break


Gas Engine Control Module Sealed customer connectors

eliminate terminal blocks Cat-standard service tool

connector is common to other Cat electronics


Integrated Combustion Sensing Module G3600 & G3520B only One per bank to read thermocouples

& combustion probes Feeds cylinder data directly to ECM Individual cylinder protection from

detonation (independent ignitiontiming retard)

What does it do?– Protects engine operations and extends life.


ADEM A3 Design Features Ignition & detonation

wiring in foam-filled rail Continuous yellow

braid wiring harness(except for cylinderhead thermocouples)

G3600


Air/Fuel Ratio Control– Allow improved control over the Air-Fuel Mixture to regulate the performance limits of

engine such as the detonation limits– To lower overall NOx levels– Automatically maintain NOx emissions– Rich Burn To provide combustion and emission control to allow use of a three-way

catalyst setting– Lean Burn Lower and Constant emissions across speed and load for NOx setting

Active control monitors engine operating parameters to maintain desired air/fuel ratio as conditions change

Effective for a limited range of LHV's

Engine Models Include: G3606, G3608, G3612, G3616

G3600 Family Slides


Air/Fuel Ratio Control


Electronic Air/Fuel Ratio Control (AFRC) Caterpillar designed

Low pressure, carburetor fuel mixing

Oxygen sensor feedback

CSA certification (Class I, Division II, Group D)

Closed-loop control designed to regulate emissions that adjusts Air/Fuel Ratio to prevailing conditions to regulate exhaust emissions.


Electronic Air/Fuel Ratio Control (AFRC) Caterpillar designed

Low pressure, IMPCO carburetor fuel mixing

Oxygen sensor feedback

CSA certification (Class I, Group D, Division II

Closed-loop control designed to regulate emissions that adjusts Air/Fuel Ratio to prevailing conditions to regulate exhaust emissions.


Lean Burn Design Option Higher BMEP Low Pressure Fuel System High/low CR- leads to better fuel flexibility AFRC allows engine to operate and maintain emissions

control in ambient conditions Detonation Protection

G3600 Family Slides


Lean Burn Engines Lean Burn

– Reduced Maintenance Costs• Lower combustion temperature results in longer cylinder

head life and exhaust system component life• More detonation tolerance results in longer ring and piston

life • Less oil degradation (less heat, lower NOx and CO, less

contaminants in oil)– Reduced Operating Costs

• Lower fuel consumption (higher efficiency)

Engine Models Include: G3606, G3608, G3612, G3616

G3600 Family Slides

Caterpillar Natural Gas Compression Engines Library Section .ppt

Documents

Transcript of Caterpillar Natural Gas Compression Engines Library Section .ppt